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Filling Big Bags with baby milk powders hygienically in clean rooms

Global demand for premium-quality baby milk powders is rising, and milk production in Europe is expected to increase due to the elimination of milk quotas in the EU. This will create opportunities for European milk powder producers, who are not only market leaders but also have the best knowledge and reputation in this sector. Dinnissen Process Technology already has an enviable track record in filling Big Bags with baby milk powders for leading companies such as Danone, Nestlé and Royal FrieslandCampina. Dinnissen has now developed an innovative technology specifically for the purpose of filling Big Bags hygienically in clean rooms in order to control the end quality of the production process and extend the shelf life of the final product. The new concept focuses on optimizing and maintaining the cleanliness of the clean rooms, implementing extra hygienic measures during the filling process, and preventing contamination via pallets.

Specialist in high care handling of baby milk powders via Big Bags
The application of Big Bag technology has risen dramatically since it was first introduced. The use of Big Bags offers producers of baby milk powders excellent opportunities to package their products economically, hygienically and safely and provides them with a great many logistic benefits. Dinnissen Process Technology specializes in providing the baby milk powder sector with a wide range of solutions for emptying, filling, sealing, and moving Big Bags. It supplies off-the-shelf products as well as fully customized solutions for packaging products quickly, hygienically, safely, and efficiently in terms of logistics. Dinnissen offers these solutions as part of the client's overall process or as a standalone project, with capacities ranging from filling only one Big Bag per week to 50 per hour. The range of products offered by Dinnissen includes a wide variety of options for packaging and processing the most extreme, hazardous or hygienically sensitive products using Big Bags. The combination of dedicated knowledge and hands-on experience enabled the company to develop its new and innovative solutions for filling Big Bags with premium-quality baby milk powders.

Ultra-hygienic conditions for connecting Big Bags in pallet-free clean rooms
The process of filling Big Bags with baby milk powder starts with ensuring that the clean room is ultra clean and remains ultra clean. The Big Bag filling concept created by Dinnissen therefore starts by ensuring that dirt-sensitive pallets are kept out of the clean room. During the filling process, Big Bags are transported via a special guidance system which minimizes the risk of contact with any type of contaminant. The system used to suspend the Big Bags during the filling process makes it very easy to clean the clean room as thoroughly and frequently as necessary. The first step in filling the Big Bag involves connecting the bag and its clean inner liner to the filler head. This is done using the special decontamination module developed by Dinnissen which safely and securely eliminates dust and dirt particles until the hose used to fill or empty the bag has been securely attached via a special inflatable seal that prevents any dust or other particles from entering or leaving the bag. The bag is then emptied of air by vacuum, after which it is filled with nitrogen or CO2 until it reaches its desired shape. The end result is a clean and oxygen-free (<1%) environment that extends the shelf life of food products. Pre-shaping the Big Bag, if necessary with the help of vibration, also ensures that the entire bag is optimally filled - securely and consistently.

Filling Big Bags safely, securely, and precisely
In order to fill Big Bags ultra-hygienically, it's important to work quickly and precisely and to prevent any particles from escaping. Dinnissen has developed special solutions to accomplish this. For example, large quantities of product can be fed into the system quickly and precisely either from a weighing bunker or directly. To comply with even more rigorous requirements in terms of safety and hygiene, the filling station can also be fitted with an integrated and high-capacity screening system, a metal detector, and/or a fully automated sampling unit. The product dosage system used by Dinnissen is based on several components, of which the "Feedervalve" developed by Dinnissen is the most important. This dosage seal valve has an excellent reputation for its precision and ability to prevent product damage. Various weighing systems, level sensors, and maximum level alarms are used to ensure reliable and accurate measurements of volume and weight. A vacuum lance can be used to remove air from products that are difficult to compact. If precise calibration is important, Dinnissen can also supply clients with the required technology and equipment and assist them with successfully navigating calibration procedures all over the world. Dinnissen also offers Big Bag stations with integrated tracking and tracing systems, including barcode scanning options and the ability to automatically block the Big Bag stations via Profibus or Ethernet. To ensure that no product escapes and contaminates the clean room, Dinnissen uses a specially shaped filler head, an inflatable seal, and the effective removal of fine particles via suction. The option of pneumatically sealing the filler hose before disconnecting it is also an effective method of preventing any contamination of the high care environment.

Airtight closure via Triple-seal technique and pick-and-place of the Big Bags
The last step in the process of hygienically filling the Big Bags is the automatic airtight sealing of the inner liner via the Triple-seal technique. This method guarantees that the oxygen concentration in the Big Bags will remain low for weeks at a time with the help of pre-gassing or post-gassing. The Big Bag can then be sealed and supplied with a clean bottom plate, after which it is transported out of the clean room via a special guidance system. This is done with the help of a special fast-closing door and the use of forced ventilation. While the door is being opened and closed, filtered and conditioned air is blown in a laminar direction at a speed of 0.4 to 0.5 m/s. For medium or low care environments, the Big Bag is placed on a pallet and entered into the logistics process. For this part of the production process Dinnissen offers systems for automatically introducing Big Bags, pallets, and packaging materials via special dispensers as well as solutions for loading and stacking Big Bags in sea containers or trucks. These systems allow companies to reduce labour costs and also ensure them of properly stowed and stable loads.

Operational efficiency and quality
Speed and efficiency are essential when it comes to ensuring that production processes remain profitable. Accordingly, Dinnissen also focuses a great deal of attention on ergonomic aspects in connection with its Big Bag filling stations. Control elements can, for example, be installed at the same height, and hooks, swivelling filler heads and twister heads can be placed in easily accessible locations. Solutions are also available for ensuring that Big Bags are automatically coded and sampled for tracking and tracing, metal detection, and the integration of control screens. It goes without saying that Dinnissen's Big Bag systems comply with all Atex, HACCP and GMP guidelines.

About Dinnissen

Dinnissen Process Technology offers you a unique mix of expertise plus contracting and manufacturing facilities: from a stand-alone machine to a complete turnkey system, from pre-engineering to project management, and from design to assembly to start-up. Our one-stop shopping concept enables us to operate independently of third-party suppliers. Our extensive international network ensures that we can deliver anywhere in the world.

Wednesday June, 28
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